An Applied Research On Lean Production Under Customization Manufacturing Settings Of S-company

This paper aims to search for the application of various tools in lean production,which in a circumstance of highly customized manufacture,it optimizes the production lead time,work-inprogress(WIP)and on-time delivery rate(OTD)and describes in detail about combination of lean and customized manufacture.This research expands the application scope of lean production theory and provides new direction for the improvement customized manufacture.The research in this paper is based on the theory of lean production.It analyzes and improves the production status of S-company with customized characteristics.The application of lean production methodologies is mainly including the following aspects:(1)Applying the “Pull” production method to the circumstance of customized manufacture,by defining information flow through the whole supply chain and frozen zone of production planning,designing KANBAN for customized product,the logistics and information flow have been stabilized.Consequently,the production activities have been “balanced”,“synchronized” and “sequenced”,reducing work-in-progress and lead time.(2)Applying “One-Piece-Flow” to the assembly and testing of customized products,by analyzing the process time of various production and comparing with the takt time,the maximum deviation of process time without blocking the flowline is calculated.By implementing the buffer area,multi-skill worker,and other management measures to strengthen the flow of the line.Also,by changing the method of transportation,the waiting and transportation waste in the area have been reduced.Thereby further optimizing the quantity of WIP and OTD.(3)The analysis of the two processes with long process time was carried out,distinguish the "internal" and "external" activities of the operation were performed by "Single Minute Exchange Die(SMED)".Afterwards,a standard operation procedure has been worked out for avoiding errors and parallel operations.Thus,the process time has been reduced,and investment of new machine has been saved.(4)Applying the “Quick Response” process to the production system,by analyzing frequency of interruption data,designing a process for low impact but high frequent problems,and using digital methods to establish an "Andon" system for such information flow,ensuring these problems are all tracked and solved.(5)Applying the modular standard working time system for customized products.Improving the accuracy of standard working time by enhancing the data level from the product capacity to basic operating unit.This system provides the fundamental data for production planning and further improvement activities.This paper applies the methodologies of lean production by merging the characteristics of customized products,provides better understanding for further research of lean management.